US6966436B2 - Absorbent mats for food packaging - Google Patents
Absorbent mats for food packaging Download PDFInfo
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- US6966436B2 US6966436B2 US10/427,282 US42728203A US6966436B2 US 6966436 B2 US6966436 B2 US 6966436B2 US 42728203 A US42728203 A US 42728203A US 6966436 B2 US6966436 B2 US 6966436B2
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- absorbent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
- B32B37/0084—Point bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/24—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants
- B65D81/26—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators
- B65D81/264—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators for absorbing liquids
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/407—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing absorbing substances, e.g. activated carbon
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/04—Punching, slitting or perforating
- B32B2038/047—Perforating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/70—Food packaging
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1334—Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
Definitions
- the present invention relates generally to packaging and, more particularly, to food packaging for improving the appearance of and protecting various food products.
- U.S. Pat. No. 6,171,695 describes an absorbent core bonded to a film top layer.
- the absorbent core includes multiple layers of absorbent tissue paper calendared or embossed together.
- the laminate is held together by either mechanical forces or hydrogen bonding.
- the multiple layers absorb exuded liquids and expand.
- the tissue paper layers may delaminate when wet and may not hold moisture well under pressure.
- U.S. Pat. No. 5,250,310 describes a bi-layer absorbent pad having an absorbent core topped with a barrier layer of film or hydrophobic nonwoven material. Unfortunately, the absorbent pad is prone to delamination when wet. In addition, the absorbent media may break away and contaminate a food product, which is unsanitary and undesirable.
- U.S. Pat. No. 4,756,939 describes an absorbent pad having absorbent media enclosed within a barrier material, such as plastic film.
- the film is perforated to allow liquids to seep in and be absorbed.
- absorbent pads of this type may be slow to absorb liquids and are typically available only in pre-determined sizes, which may lead to liquid under absorption within a food package.
- These pouch type pads may contain superabsorbent material such as powder, granule, or fiber.
- the enclosed pouch is thought to be necessary to control the gel that results from the wetting of the superabsorbent material.
- the enclosed pouch also may expand or rupture when used for vacuum packaging or modified atmosphere packaging. This rupture can contaminate the package and, at times, can contaminate the production area.
- a multi-layer absorbent mat for use within a food product package includes top and bottom layers of thermoplastic material and absorbent media disposed between the top and bottom layers.
- the top and bottom layers are thermally bonded directly together through the absorbent media at multiple, spaced-apart sites.
- the top and bottom layers of thermoplastic material may be thermally bonded to absorbent media disposed therebetween via binder fibers in the absorbent media.
- Each bond site is defined by a bond portion where the top and bottom layers are thermally bonded directly together through the absorbent media and a peripheral portion adjacent to the bond portion.
- One or more ruptures or perforations are formed as a result of thermal bonding in at least one of the top or bottom layers in the peripheral portion of each bond site.
- Each perforation is in communication with the absorbent media and provides a pathway through which liquid can pass from external to the mat into the absorbent media.
- the top and bottom layers may be sealed (e.g., heat sealed, ultrasonically sealed, etc.) together along respective peripheral edges thereof to further contain the absorbent media.
- either or both of the top and bottom layers may be formed from nonwoven material or from monolithic polymeric film.
- Each layer may have a thickness of between about 0.3 mils and about 10.0 mils.
- a multi-layer absorbent mat includes top and bottom layers of substantially liquid impermeable (i.e., monolithic) thermoplastic film, and absorbent media disposed between the top and bottom layers.
- the top and bottom layers are thermally bonded directly together through the absorbent media at multiple, spaced-apart bond sites.
- Each bond site is defined by a bond portion where the top and bottom layers are thermally bonded directly together through the absorbent media and a peripheral portion adjacent to the bond portion.
- An aperture is formed through the top and bottom layers at each respective bond site by substantially evenly stretching the multi-layer absorbent mat via various devices and methodologies (e.g., bow rolls, tentering, ring rolls, interdigitating rolls spreader rolls, etc.) by an amount between about one percent and about seventy percent (1%-70%) of a relaxed configuration thereof.
- One or more ruptures or perforations are formed in the peripheral portion of each bond site thereof as a result of stretching. Each perforation is in communication with the absorbent media and provides a pathway through which liquid can pass from external to the mat into the absorbent media.
- FIG. 1A is a perspective view of a multi-layer absorbent mat according to embodiments of the present invention.
- FIG. 1B is an enlarged plan view of a bond site in the multi-layer absorbent mat of FIG. 1 A.
- FIG. 1C is a cross-sectional view of the bond site of FIG. 1B taken along lines 1 C— 1 C.
- FIG. 1D is a cross-sectional view of the bond site of FIG. 1B according to another embodiment of the present invention wherein the top and bottom layers are bonded to the absorbent media disposed therebetween via binder fibers in the absorbent media.
- FIG. 2A is a perspective view of a multi-layer absorbent mat according to other embodiments of the present invention.
- FIG. 2B is an enlarged plan view of a bond site in the multi-layer absorbent mat of FIG. 2 A.
- FIG. 2C is a cross-sectional view of the bond site of FIG. 2B taken along lines 2 C— 2 C.
- FIG. 3 is a graph illustrating the relationship of absorbency and stretch level for the multi-layer absorbent mat of FIGS. 2A-2C .
- FIG. 4 is an exploded perspective view of a food product package incorporating a multi-layer absorbent mat, according to embodiments of the present invention.
- FIG. 5 is a perspective view of the food product package of FIG. 4 including a food product and a surrounding plastic wrap.
- nonwoven web refers to a web that has a structure of individual fibers or threads which are interlaid, but not in any regular, repeating manner.
- Nonwoven webs may be formed by a variety of processes, such as, for example, meltblowing processes, spunbonding processes and bonded carded web processes.
- the term “superabsorbent” refers to a special group of polymers that have the ability to absorb many times their own mass of liquid. Superabsorbents are configured to swell very rapidly in liquid, but not dissolve.
- polymer generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
- polymer shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiaotactic and random symmetries.
- the illustrated mat 10 includes top and bottom layers 12 , 14 of substantially liquid impermeable (i.e., monolithic) thermoplastic film, and absorbent media 16 disposed between the top and bottom layers 12 , 14 .
- the top and bottom layers 12 , 14 are thermally bonded directly together through the absorbent media 16 at multiple, spaced-apart bond sites 18 , as illustrated in FIG. 1 C.
- the top and bottom layers 12 , 14 are bonded to the absorbent media 16 at multiple, spaced-apart bond sites 18 via binder fibers in the absorbent media 16 , as illustrated in FIG. 1 D.
- Each bond site 18 is defined by a bond portion 20 where the top and bottom layers 12 , 14 are thermally bonded directly together through the absorbent media 16 and a peripheral portion 22 adjacent to the bond portion 20 . Fibers within the absorbent media 16 typically protrude from the top and bottom layers 12 , 14 at the bond portion 20 .
- One or more ruptures or perforations 24 are typically formed in at least one of the top or bottom layers 12 , 14 in the peripheral portion 22 , as a result of thermal bonding.
- Each perforation 24 is in communication with the absorbent media 16 and provides a pathway through which liquid can pass from external to the mat 10 into the absorbent media 16 .
- An enlarged bond site 18 is illustrated in FIGS. 1B-1C and illustrates perforations 24 formed in the bond peripheral portion 22 .
- the top and bottom layers 12 , 14 are thermally bonded together at multiple, spaced-apart locations or sites.
- other attachment methods may be utilized including, but not limited to, ultrasonic bonding, mechanical bonding, or other attachment means or combinations of these attachment means as are known in the art.
- the bond sites 18 may have various configurations and patterns.
- the total bond area i.e., the total area of all bonds
- the total bond area is preferably between about five percent and about fifty percent (5%-50%) of the area of the top and bottom layers 12 , 14 , and more preferably between about ten percent and about twenty five percent (10%-25%) of the area of the top and bottom layers 12 , 14 .
- the top and bottom layers 12 , 14 may be sealed (e.g., heat sealed, ultrasonically sealed, etc.) together along respective peripheral edges 12 a , 14 a thereof to further contain the absorbent media 16 .
- Thermal bonding is performed using sufficient force to bond the top layer 12 through to the bottom layer 14 .
- the bonding may be enhanced by the incorporation of compatible thermoplastic fiber(s) into the absorbent media 16 . When thick or heavy absorbent media 16 is utilized, this may be necessary to ensure adequate bonding.
- the force is determined in individual cases depending on the nature of the absorbent media 16 .
- the absorbent media may or may not participate in the thermal bonding; however, when fibers in the absorbent media 16 do participate, the bonding is typically more secure. Each bond site forms a visible deformation of the structure even when the top and bottom layers are bonded to the absorbent media in lieu of each other.
- Thermal bonding may be performed using an engraved roll over a smooth roll, or matched engraved rolls, as would be understood by those skilled in the art of thermal bonding.
- Multiple spaced-apart bonding as illustrated in FIG. 1A can help prevent crushing or compressing of the absorbent media 16 . Compression can reduce the void volume of the absorbent media 16 and limit the swelling of super-absorbent polymers in the absorbent media 16 .
- the spaced-apart thermal bond sites 18 also reduce the damage to the absorbent capacity that may occur when adhesives are used.
- the absorbent media 16 may be manufactured from a wide variety of liquid-absorbent materials including, but not limited to, wood pulp, creped cellulose wadding, meltblown polymers including coform, nonwoven fabric structures such as thermal bond or resin bond that contain absorbent fiber or superabsorbent particles or fibers, chemically stiffened, modified or cross-linked cellulosic fibers, tissue including tissue wraps and tissue laminates, absorbent foams, absorbent sponges, super-absorbent polymers, absorbent gelling materials, or any equivalent material or combinations of materials.
- Exemplary absorbent media are disclosed in U.S. Pat. Nos. 5,260,345; 5,268,224; and 5,628,097, each of which is incorporated herein by reference in its entirety.
- the absorbent media 16 may include tissue, tissue containing super-absorbent polymer, air-laid pulp, air-laid pulp with super-absorbent fiber or powder, absorbent nonwovens, or foams. Suitable air-laid pulps are available from Concert Industries and from Fort James Corporation. The use of air-laid pulp with super-absorbent fiber is preferred.
- the air-laid pulp material may be bonded with thermoplastic binder fiber, or with sprayed, printed, or coated binder. Suitable grades of air-laid pulp include Concert Industries' grade EDT.150.105.AS1359, or EDT 160.101.BS1359. Additionally, the absorbent media 16 may include super-absorbent polymer(s) in the form of a fiber, powder, flake, particle, or granule, or other form.
- Suitable absorbent nonwovens include needlepunched rayon or tencel, which are available from American Nonwovens, Columbus, Miss. Suitable tissues are available from Procter & Gamble and Cellutissue Corporation. Tissues may range from about ten grams per square meter to about sixty grams per square meter (10-60 gsm). A suitable product is Grade 3141-33, 20 gsm, single ply white ultra absorbent laminating core tissue from Interlake.
- binder fibers are present in the absorbent media 16 , the binder fibers and the top and bottom layers 12 , 14 are preferably compatible to facilitate thermal bonding. Coextruded materials such as polypropylene/polyethylene, polyester/polyethylene, and polyester/polypropylene fibers are preferred binder fibers.
- the absorbent media 16 includes wood pulp 16 a , superabsorbent fibers 16 b and binder fibers 16 c.
- the absorbent media 16 has a liquid capacity of at least about ten grams of liquid per one gram of absorbent media (10 g/1 g).
- the absorbent media 16 may include thermoplastic material that is compatible with the thermoplastic material of the top and bottom layers 12 , 14 . This compatible material facilitates bonding between the top and bottom layers 12 , 14 .
- one or more of the top and bottom layers 12 , 14 may be formed from nonwoven material or from monolithic polymeric film.
- Each layer 12 , 14 may have a thickness, for example, of between about 0.3 mils and about 10.0 mils.
- Exemplary nonwoven materials that may be utilized include spunbonded webs, meltblown webs, and/or bonded carded webs.
- a nonwoven web according to embodiments of the present invention may include synthetic fibers (e.g., nylon, polyester, acrylic, polyolefin, polyethylene, polypropylene, modacrylic, polyvinyl chloride, polyvinylidene chloride, urethane, copolyether ester, copolyether amide, polyolefin, etc.), natural fibers (e.g., wood fibers, cotton fibers, etc.), or a blend of synthetic and natural fibers.
- a nonwoven web according to embodiments of the present invention may be made of fiber forming polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.
- spunbonded fabric includes CELESTRA® brand spunbonded polypropylene from BBA Corporation, or SOFTEX® brand coextruded polypropylene core polyethylene sheath spunbond.
- Polyethylene spunbond such as DALTEX® brand spunbond from Don & Low Corporation is also a preferred material.
- thermoplastic fibers and non-thermoplastic fibers may be utilized if the blended fabrics are capable of being thermally bonded. If a high percentage of non-thermoplastic fiber is not present or if bond strength is lower than desired, a bond improving additive such as a thermoplastic powder adhesive, or a binder fiber, may be added to the web.
- Exemplary monolithic polymeric films include, but are not limited to polyethylene, polypropylene, polyolefin, nylon, polyester, acrylic, modacrylic, polyvinyl chloride, polyvinylidene chloride, urethane, copolyether ester, and copolyether amide.
- a thermoplastic mesh or netting may also be used. Suitable plastic netting is available from Delstar, Inc. as DELNET® brand netting, and from Smith & Nephew, Inc., and Conwed, Inc. Additionally, formed perforated films may be used such as the VISPORE® brand films from Tredegar, Inc.
- the illustrated mat 110 includes top and bottom layers 112 , 114 of substantially liquid impermeable (i.e., monolithic) thermoplastic film, and absorbent media 116 disposed between the top and bottom layers 112 , 114 .
- the top and bottom layers 112 , 114 are thermally bonded directly together through the absorbent media 16 at multiple, spaced-apart bond sites 118 , as illustrated.
- the top and bottom layers 112 , 114 are thermally bonded to the absorbent media 16 at multiple, spaced-apart bond sites 118 , via binder fibers in the absorbent media 16 .
- Each bond site 118 is defined by a bond portion 120 where the top and bottom layers 112 , 114 are thermally bonded directly together through the absorbent media 116 and a peripheral portion 122 adjacent to the bond portion 120 .
- other attachment methods may be utilized including, but not limited to, ultrasonic bonding, mechanical bonding, or other attachment means or combinations of these attachment means as are known in the art.
- the total bond area i.e., the total area of all bonds
- the total bond area is preferably between about five percent and about fifty percent (5%-50%) of the area of the top and bottom layers 112 , 114 , and more preferably between about ten percent and about twenty five percent (10%-25%) of the area of the top and bottom layers 112 , 114 .
- the top and bottom layers 112 , 114 may be sealed (e.g., heat sealed, ultrasonically sealed, etc.) together along respective peripheral edges 112 a , 114 a thereof to further contain the absorbent media 116 .
- Thermal bonding is performed using sufficient force to bond the top layer 112 through to the bottom layer 114 .
- the bonding may be enhanced by the incorporation of compatible thermoplastic fiber(s) into the absorbent media 116 . When thick or heavy absorbent media 116 is utilized, this may be necessary to ensure adequate bonding.
- the force is determined in individual cases depending on the nature of the absorbent media 116 .
- the absorbent media may or may not participate in the thermal bonding; however, when fibers in the absorbent media 16 do participate, the bonding is typically more secure.
- Thermal bonding may be performed using various techniques, including those described above with respect to the mat 10 of FIGS. 1A-1C .
- the top and bottom layers 112 , 114 may be formed from various monolithic polymeric films as described above with respect to the mat of FIGS. 1A-1C .
- Each layer 112 , 114 may have a thickness, for example, of between about 0.3 mils and about 10.0 mils.
- the absorbent media may include various materials as described above with respect to the mat of FIGS. 1A-1C .
- a multi-layer absorbent mat 110 may be substantially evenly stretched by passing the mat 100 through interdigitated rolls.
- An exemplary method using interdigitated rolls is described in U.S. Pat. No. 5,628,097 which is incorporated herein by reference in its entirety.
- Other methods of stretching include, but are not limited to, stretching via bow rolls and tenter framing. Stretching may be performed in one or more directions, and either substantially simultaneously or sequentially.
- Other exemplary stretching processes are disclosed in U.S. Pat. Nos. 4,368,565 and 4,116,892, each of which is incorporated herein by reference in its entirety.
- FIGS. 2B-2C An enlarged bond site 118 is illustrated in FIGS. 2B-2C and illustrates an aperture 130 formed at a bond site 118 .
- One or more ruptures or perforations 124 are formed in the peripheral portion 122 of each bond site thereof, as illustrated in FIGS. 2B-2C .
- Each perforation 124 is in communication with the absorbent media 116 and provides a pathway through which liquid can pass from external to the mat 110 into the absorbent media 116 .
- various fibers from the absorbent media 116 may protrude through the perforations 124 formed in the peripheral portion 122 of each bond site 118 .
- a mat according to embodiments of the present invention increases with stretch level, as illustrated in FIG. 3 .
- a mat according to embodiments of the present invention can be stretched so as to fully cover the tray of a food product package and so as to have increased absorbency over an unstretched mat.
- the illustrated food product package 200 includes a tray 210 and a multi-layer absorbent mat 10 , 110 .
- the tray 210 has a bottom wall 214 and a raised rim 215 .
- the multi-layer absorbent mat 10 , 110 is disposed on the tray bottom wall 214 and is configured to absorb liquids exuded from food products placed thereon via the perforations 24 , 124 formed at each bond site 18 , 118 as described above.
- an overwrap of flexible film material 217 covers a food product FP placed on the mat 10 , 110 within the tray 210 .
- mats according to embodiments of the present invention can have their peripheral edges sealed together. As such, absorption of liquids from food products via perforations 24 , 124 is extremely efficient and effective.
- Mats 10 , 110 may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, circular, oval, hourglass, “T”-shaped, asymmetric, etc.), and can be adapted to any type and shape of food product being packaged.
- the layers 12 , 112 and 14 , 114 need not be identical in shape or composition.
- the layers 12 , 112 and 14 , 114 maintain separation between a food product FP and the absorbent media 16 , 116 . This prevents contamination of the food product FP with particles from the absorbent media and allows for easy separation of the food product from the mat 12 without causing delamination of the mat 10 , 110 , even when frozen.
- a highly absorbent structure comprised of an airlaid nonwoven sandwiched between two monolithic films was produced.
- the individual film and airlaid layers were passed between a patterned calendar roll and a smooth anvil roll.
- the patterned calendar roll produced multiple spaced apart bond sites.
- the bond pattern coupled with temperature and pressure resulted in a structure where the two thermoplastic layers were bonded through the absorbent core. This airlaid was encapsulated between the bond site areas. Bonding temperature was 200° F. for both the patterned and smooth calendar rolls. Pressure in the calendar nip was approximately 600 psi.
- the airlaid nonwoven was produced by Concert Industries (style 130.2382) and had a basis weight of 130 gsm.
- the airlaid was comprised of 30% super absorbent fiber, 16% polyethylene/polyester bicomponent fiber (sheath/core), and 64% wood pulp.
- the films were both 0.5 mil low density polyethylene (style FT220) embossed films manufactured by Filmtech. Gross absorbency in deionized water using a 1 minute dunk and a 1 minute drip is shown below in Table 1.
- Highly absorbent porous structures comprised of an airlaid nonwoven sandwiched between two monolithic films were produced.
- the individual film and airlaid layers were passed between a patterned calendar roll and a smooth anvil roll.
- the patterned calendar roll produced multiple spaced apart bond sites.
- the bond pattern coupled with temperature and pressure resulted in a structure where two thermoplastic layers were bonded through the absorbent core. This airlaid was encapsulated between the bond site areas. Bonding temperature was 200° F. for both the patterned and smooth calendar rolls. Pressure in the calendar nip was approximately 600 psi.
- the airlaid nonwoven was produced by Concert Industries (style 130.2382) and had a basis weight of 130 gsm.
- the airlaid was comprised of 30% super absorbent fiber, 16% polyethylene/polyester bicomponent fiber (sheath/core), and 64% wood pulp.
- the films were both 0.5 mil low density polyethylene (style FT220) embossed films manufactured by Filmtech Corporation.
- FIG. 3 shows a steady increase in the absorbency as the stretch is increased.
- the absorbency of the products is often measured in saline solutions of from 0.05% to 1%. These saline levels are seen in the fluids that leach from meat when packed for sale.
- the absorbency of the super-absorbent fibers is reduced by saline content and therefore the blend of cellulose fibers with super-absorbent fibers is used.
- the composition of the absorbent layer may be adjusted appropriately.
Abstract
Description
TABLE 1 | |||||
Absorbency in | Absorbency in | ||||
Weight | Thickness | Deionized Water | Deionized Water | ||
(gsm) | (in) | (gwater/gfabric) | (g/in2) | ||
159.2 | 0.040 | 25.8 | 2.65 | ||
TABLE 2 | |||||
Basis | Absorbency in | Absorbency in | |||
Weight | Thick- | Deionized | Deionized | ||
Ex- | Stretch | w/o film | ness | Water | Water |
amples | (%) | (gsm) | (in) | (g/in2) | (gwater/gfabric) |
1 | 0.0 | 159.2 | 0.040 | 2.65 | 25.8 |
2 | 5.5 | 140.6 | 0.040 | 2.68 | 29.6 |
3 | 7.2 | 148.7 | 0.044 | 3.12 | 32.6 |
4 | 9.8 | 146.0 | 0.046 | 2.98 | 31.6 |
5 | 13.1 | 139.2 | 0.045 | 2.74 | 30.6 |
6 | 17.3 | 132.7 | 0.046 | 3.05 | 35.6 |
7 | 24.8 | 126.4 | 0.048 | 2.78 | 34.1 |
8 | 32.2 | 110.3 | 0.052 | 2.54 | 35.9 |
9 | 40.7 | 111.9 | 0.048 | 2.73 | 37.8 |
Claims (31)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/427,282 US6966436B2 (en) | 2003-05-01 | 2003-05-01 | Absorbent mats for food packaging |
PCT/US2004/004081 WO2004099009A2 (en) | 2003-05-01 | 2004-02-12 | Improved absorbent mats for food packaging |
US11/119,674 US7306094B2 (en) | 2003-05-01 | 2005-05-02 | Absorbent mats for food packaging |
US11/924,244 US20080041737A1 (en) | 2003-05-01 | 2007-10-25 | Absorbent Mats for Food Packaging |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/427,282 US6966436B2 (en) | 2003-05-01 | 2003-05-01 | Absorbent mats for food packaging |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/119,674 Division US7306094B2 (en) | 2003-05-01 | 2005-05-02 | Absorbent mats for food packaging |
Publications (2)
Publication Number | Publication Date |
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US20040226834A1 US20040226834A1 (en) | 2004-11-18 |
US6966436B2 true US6966436B2 (en) | 2005-11-22 |
Family
ID=33415950
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/427,282 Expired - Fee Related US6966436B2 (en) | 2003-05-01 | 2003-05-01 | Absorbent mats for food packaging |
US11/119,674 Expired - Fee Related US7306094B2 (en) | 2003-05-01 | 2005-05-02 | Absorbent mats for food packaging |
US11/924,244 Abandoned US20080041737A1 (en) | 2003-05-01 | 2007-10-25 | Absorbent Mats for Food Packaging |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/119,674 Expired - Fee Related US7306094B2 (en) | 2003-05-01 | 2005-05-02 | Absorbent mats for food packaging |
US11/924,244 Abandoned US20080041737A1 (en) | 2003-05-01 | 2007-10-25 | Absorbent Mats for Food Packaging |
Country Status (2)
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US (3) | US6966436B2 (en) |
WO (1) | WO2004099009A2 (en) |
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US20050191462A1 (en) * | 2003-05-01 | 2005-09-01 | Precision Fabrics Group, Inc. | Absorbent mats for food packaging |
US20080199577A1 (en) * | 2007-02-21 | 2008-08-21 | Paper-Pak Industries | Consumer food storage package with absorbent food pad |
US20100047405A1 (en) * | 2007-02-21 | 2010-02-25 | Sayandro Versteylen | Absorbent pad to preserve freshness for consumer food storage |
US20110165294A1 (en) * | 2008-03-07 | 2011-07-07 | Sayandro Versteylen | Absorbent pads for food packaging |
US20120085661A1 (en) * | 2010-10-12 | 2012-04-12 | Cellcomb Ab | Pouch type food pad and food tray |
US10882295B2 (en) | 2018-03-09 | 2021-01-05 | Novipax Llc | Absorbent fluff and tissue laminate pads for food packaging |
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Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
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US20050191462A1 (en) * | 2003-05-01 | 2005-09-01 | Precision Fabrics Group, Inc. | Absorbent mats for food packaging |
US7306094B2 (en) * | 2003-05-01 | 2007-12-11 | Precision Fabrics Group, Inc. | Absorbent mats for food packaging |
US20080199577A1 (en) * | 2007-02-21 | 2008-08-21 | Paper-Pak Industries | Consumer food storage package with absorbent food pad |
US20100047405A1 (en) * | 2007-02-21 | 2010-02-25 | Sayandro Versteylen | Absorbent pad to preserve freshness for consumer food storage |
US9364119B2 (en) | 2007-02-21 | 2016-06-14 | Paper-Pak Industries | Absorbent pad to preserve freshness for consumer food storage |
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US20120085661A1 (en) * | 2010-10-12 | 2012-04-12 | Cellcomb Ab | Pouch type food pad and food tray |
US10882295B2 (en) | 2018-03-09 | 2021-01-05 | Novipax Llc | Absorbent fluff and tissue laminate pads for food packaging |
US11794464B2 (en) | 2018-03-09 | 2023-10-24 | Novipax Buyer, Llc | Absorbent fluff and tissue laminate pads for food packaging |
Also Published As
Publication number | Publication date |
---|---|
US20050191462A1 (en) | 2005-09-01 |
US20080041737A1 (en) | 2008-02-21 |
WO2004099009A2 (en) | 2004-11-18 |
US20040226834A1 (en) | 2004-11-18 |
US7306094B2 (en) | 2007-12-11 |
WO2004099009A3 (en) | 2005-08-11 |
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